Manifold for heat exchanger and baffles therefor

A manifold for a heat exchanger, said manifold being tubular in form and having two ends and a longitudinal axis and comprising:

• an elongated manifold segment inset from said ends of said manifold, said manifold segment having an inner surface defining an interior and a longitudinal axis collinear with said longitudinal axis of said manifold, said manifold segment further having a plurality of parallel spaced slots formed therein, adjacent slots defining a web therebetween, each of said webs having at least two depressions extending into said interior of said manifold segment, said depressions being positioned on either side of a plane bisecting said slots and intersecting said manifold longitudinal axis, said manifold segment having a circular cross-section interrupted at said webs by a relatively flat profile so that said manifold segment and said inner surface thereof have an approximately D-shaped profile in transverse cross-section;
• at least one baffle, said baffle having a principle circular edge and a truncated edge with a radius of curvature substantially greater than the rest of the baffle perimeter so as to have a truncated circular profile substantially corresponding to the transverse cross-section of the inner surface of the manifold segment, with a slight gap between at least a portion of the baffle perimeter and the inner surface of the manifold segment, said baffle having an outwardly extending lip over a portion of its perimeter at said principle circular edge, wherein said lip has opposed ends and projections extending radially outwardly from said ends, said projections being dimensioned to provide an interference fit between said baffle and the manifold segment, and said baffle perimeter is dimensioned to define a slight gap with said inner surface of said manifold segment except at said projections;
• and
• a fillet of filler material filling the gap between each of said baffles and said manifold segment.